Energy storage device

Patent metadata

Field	Value
Publication number	US-2021265641-A1
Application number	US-201917261526-A
Country	US
Kind code	A1
Filing date	Jul 19, 2019
Priority date	Jul 20, 2018
Publication date	Aug 26, 2021
Grant date	—

Abstract

A method comprising providing a first electrode layer on a first portion of a substrate, providing an electrolyte layer on the first electrode layer, and providing a second electrode layer on the electrolyte layer. At least part of a current collector layer is provided on a second portion of the substrate. An electrically insulating material is deposited on an exposed surface of the first electrode layer and an exposed surface of the electrolyte layer. An electrically conductive material is deposited on the electrically insulating material to connect the second electrode layer to the at least part of the current collector layer.

First claim

1 . A method of manufacturing an energy storage device, the method comprising:
providing a first electrode layer on a first portion of a substrate; providing an electrolyte layer on the first electrode layer; providing a second electrode layer on the electrolyte layer; providing at least part of a current collector layer on a second portion of the substrate; depositing an electrically insulating material on an exposed surface of the first electrode layer and an exposed surface of the electrolyte layer; and depositing an electrically conductive material on the electrically insulating material to connect the second electrode layer to the at least part of the current collector layer.

2 . The method of claim 1 , wherein the at least part of the current collector layer on the second portion of the substrate is a first portion of the current collector layer and the method comprises:
providing a second portion of the current collector layer on the first portion of the substrate before providing the first electrode layer on the second portion of the current collector layer, to provide the first electrode layer on the first portion of the substrate.

3 . The method of claim 2 , comprising providing the current collector layer on the substrate, comprising:
providing the first portion of the current collector layer on the second portion of the substrate; providing the second portion of the current collector layer on the first portion of the substrate; and providing a third portion of the current collector layer on a third portion of the substrate between the first portion of the substrate and the second portion of the substrate.

4 . The method of claim 3 , comprising, after at least one of: providing the first electrode layer on the first portion of the substrate, providing the electrolyte layer on the first electrode layer, or providing the second electrode layer on the electrolyte layer:
removing the third portion of the current collector layer to expose the third portion of the substrate.

5 . The method of claim 4 , wherein removing the third portion of the current collector layer comprises laser ablating the third portion of the current collector layer.

6 . The method of claim 1 , wherein
providing the second electrode layer is performed after depositing the electrically insulating material.

7 . The method of claim 1 , wherein at least one of:
depositing the electrically insulating material comprises ink jet printing the electrically insulating material; or depositing the electrically conductive material comprises ink jet printing the electrically conductive material.

8 . A method comprising:
providing, on a substrate, a stack for an energy storage device, the stack comprising:
a current collector layer;
an electrolyte layer; and
a first electrode layer between the current collector layer and the electrolyte layer;
removing a portion of the first electrode layer and a portion of the electrolyte layer to expose a portion of the current collector layer; removing part of the portion of the current collector layer to leave a first portion of the current collector layer not overlapped by the first electrode layer and the electrolyte layer and a second portion of the current collector layer overlapped by the first electrode layer and the electrolyte layer; depositing an electrically insulating material between the first portion of the current collector layer and the second portion of the current collector layer, and on an exposed surface of the first electrode layer and an exposed surface of the electrolyte layer; providing a second electrode layer on the electrolyte layer; and depositing an electrically conductive material on the electrically insulating material to connect the second electrode layer to the first portion of the current collector layer.

9 . The method of claim 8 , wherein depositing the electrically insulating material comprises depositing the electrically insulating material between the first portion of the current collector layer and the second portion of the current collector layer without overlapping the first portion of the current collector layer.

10 . The method of claim 8 , wherein removing the part of the portion of the current collector layer exposes a portion of the substrate, and depositing the electrically insulating material comprises depositing the electrically insulating material to contact the portion of the substrate.

11 . The method of claim 10 , wherein depositing the electrically insulating material comprises depositing the electrically insulating material to contact a first part of the portion of the substrate without contacting a second part of the portion of the substrate.

12 . The method of claim 11 , wherein depositing the electrically conductive material comprises depositing the electrically conductive material to contact the second part of the portion of the substrate.

13 . The method of claim 8 , wherein depositing the electrically conductive material comprises depositing the electrically conductive material on the electrically insulating material to connect the second electrode layer to the first portion of the current collector layer without the electrically conductive material overlapping the first portion of the current collector layer.

14 . The method of claim 8 , wherein at least one of:
removing the portion of the first electrode layer and the portion of the electrolyte layer comprises laser ablating the portion of the first electrode layer and laser ablating the portion of the electrolyte layer; or removing the part of the portion of the current collector layer comprises laser ablating the part of the portion of the current collector layer.

15 . An energy storage device formed by the method of claim 1 .

16 . An energy storage device comprising:
a substrate; a stack on a first portion of the substrate, the stack comprising:
a first electrode;
a second electrode, further from the substrate than the first electrode; and
an electrolyte between the first electrode and the second electrode;
at least part of a current collector on a second portion of the substrate, different from the first portion of the substrate; an electrically insulating material on an exposed surface of the stack to insulate the first electrode from the second electrode; and an electrically conductive material on the electrically insulating material to connect the second electrode to the at least part of the current collector.

17 . The energy storage device of claim 16 , wherein the at least part of the current collector on the second portion of the substrate is a first portion of the current collector and the energy storage device comprises a second portion of the current collector on the first portion of the substrate, between the first portion of the substrate and the stack.

18 . The energy storage device of claim 17 , wherein the electrically insulating material contacts a third portion of the substrate between the first portion of the substrate and the second portion of the substrate, to insulate the first portion of the current collector from the second portion of the current collector.

19 . The energy storage device of claim 16 , wherein a portion of the second electrode overlaps the electrically insulating material such that the electrically insulating material is at least partly between the portion of the second electrode and the substrate.

20 . An intermediate structure for manufacture of an energy storage device, the intermediate str

Assignees

• Dyson Technology Ltd

Inventors

• Howard Joseph Daniel

Classifications

• H01M6/18

  with solid electrolyte · CPC title

• H01M10/04

  Construction or manufacture in general (H01M10/058, H01M10/12, H01M10/28, H01M10/38 take precedence) · CPC title

• H01M50/586

  inside the batteries, e.g. incorrect connections of electrodes · CPC title

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M6/40 Primary

  Printed batteries {, e.g. thin film batteries} · CPC title